Station and method to store and dispense wiring components

ABSTRACT

A rack stacks rearwardly upward stepped rows of elongated openended rectangular boxes. A slidably removable divider partitions each box. From the removed divider rear along its undersurface, then around a front groove and then rearwardly over the divider is drawn a group of prepared wires. The loaded divider is inserted in the box for assembly of wires into equipment. One embodiment divider is rearwardly looped downwards to support one dangling end of long wires. The box row stepping enables separation of rows of overhanging wires into different planes. Another divider embodiment for shorter wires terminates with a box rear closure.

United States Patent DISPENSE WIRING COMPONENTS 10 Claims, 10 DrawingFigs.

US. Cl 211/128, 2| 1/49, 21 1/60, 221/34, 221/46, 221/47 Int. Cl A4713/14, A471" 7/00 Field olSenrch 211/128,

126,177, 60, 60 A, 148, 49, 49 D; 312/278, 198; 221/47, 46, 34; 206/64,63.3; 242/127; 220/22, 22.5;108/9l93 Primary ExaminerRamon S. BrittsAttorneys-James K. Haskell and Joseph P. Kates ABSTRACT: A rack stacksrearwardly upward stepped rows of elongated open-ended rectangularboxes. A slidably removable divider partitions each box. From theremoved divider rear along its undersurface, then around a front grooveand then rearwardly over the divider is drawn a group of prepared wires.The loaded divider is inserted in the box for assembly of wires intoequipment. One embodiment divider is rearwardly looped downwards tosupport one dangling end of long wires. The box row stepping enablesseparation of rows of overhanging wires into different planes. Anotherdivider embodiment for shorter wires terminates with a box rear closure.

PATENTED AUG] 7 I97! SHEET 1 OF 3 M04170: 514/410 Jade/r402;

STATION AND METHOD TO STORE AND DISPENSE WIRING COMPONENTS BACKGROUND OFTHE INVENTION The present invention relates to apparatus and a method topackage, store, and dispense groups of prepared wires in the assembly ofunits and equipments which include wire components.

In assembling units and equipments, for example, electronics apparatusand devices, the wires required to be installed into the electronicsapparatus and devices are first prepared by a preparer at a preparingstation. Preparation involves, for example, cutting the wires to length,color coding, stripping the insulation from a plurality of similar wiresat both ends, tinning the stripped ends if required, and applyingpigtails if required.

The wires necessary to build a unit of equipment are called a wire kit."A typical number of wires in a power harness wire kit, for example, isI50 wires. In the prior art methods, following the above-describedoperations at the preparing station, a number of wires equal to thenumber of equipments to be built, of each of the types of wire in thewire kit for that equipment is loaded into a separate plastic or paperbag or is bundles like wheat and confined by tape at the center and thebag or tape is identified. Groups of the bags of wires are then cartedand sent to stores or sent for handling at the assembly station.

For example, assume 10 power harnesses are to he produced and each powerharness is to contain 150 wires comprising a [-inch long wire of firstcharacteristics, a 12- inch long wire of the first characteristics, al0-inch long wire of second characteristics, etc. Then ten -inch firstcharacteristics wires are loaded into one bag or are taped, ten l2- inchfirst characteristics wires are loaded into a second bag or are taped,ten l0-inch wires second characteristics wires are loaded into a thirdbag or are taped, etc. The bags are then each identified, and are sentto the assembly station or sent to stores and loaded into cartons or onshelves. When stored, upon commencing of assembly, the bags are drawnfrom stores and brought to the assembly station. A plurality of kitscorresponding to the number of equipments to be built, e.g., 50 to I00kits, are ordered and delivered to the assembly station in this manner.

At the assembly station, the individual groups of wires are removed fromthe bags. The dispatcher pushes a group of wires of a givencharacteristic into one or into two adjacent pigeonholes of an egg cratelike structure. A typical such egg crate is a sheet metal rectangularbox open at the front and back and divided by solid fiber partitionsinto 72 rectangular cavities or pigeonholes. Where the wires are lessthan pigeonhole length, a bag of wires or several wires of the bag at atime may be pushed into a single pigeonhole. Where the wires are longerthan the pigeonholc depth the wires of a bag may be bent to form twolegs and a bight or apex. One end or leg of the wire is pushed into theleft side (facing the dispatcher) pigeonhole of a pair and the other endor leg of the wire pushed through the other pigeonhole of the pair andwhich is immediately to the right of the pigeonhole into which the firsthalf of the wire was pushed. The apex or bight formed by folding eachwire is positioned against the front divider between the pair ofadjacent pigeonholes of the egg crate.

After the dispatcher has stored the wire into the individual adjacentegg crate pigeonholes, he identifies each pair of cavities into which agroup of identical wires are positioned. The egg crates normally have 72cavities or pigeonholes which form 36 pairs. After identifying each ofthe openings for short wires and pairs of openings for long wires bymaking or attaching labels to the partition material between and overthe pairs of openings, to show identification of the separate groups ofwires, the egg crates are carted to the using station. At the usingstation an assembly operator starts pulling out the different types ofwires as needed for assembly into the electronic units to be assembled.Where the pigeonhole is not as deep as the length of the wires, the endsof the wires dangle behind the egg crate. This frequently results inproblems of entanglement. Also in pushing the ends of the wires into thepair of cavities into which the wires fit they become twisted and bentor entangled. Often in trying to pull one wire from the group in thepair of cavities, because of entanglement within the cavities due topulling bent, twisted or entangled wires and entanglement beyond thecavity, the assembler pulls more than one wire so that an additionalwire is hanging loosely partly separated from the remainder. To rectifythis the assembler normally tries to stuff one of the two wires whichare usually pulled from the cabinet or egg crate back into the cabinet.Due to the entanglement and close grouping oftentimes the assemblercannot do this readily and she or he normally throws away the secondwire (and any others pulled). This is wasteful of the wires which havebeen prepared adequately at the preparation station and imposesadditional difficulties in handling the resulting scrap wire material.

Thus the prior art method and means requires cumbersome and timeconsuming bag packing and unpacking, and egg crate stuffing, andrequires the handling of the egg crates or boxes of wires to be done atthe assembly station where time and space are at a premium. By the priorart means and method there is caused disadvantageous wire entanglement,bending and distortion, loss of time, materials, and man hours due todifficulty of handling wires, and unnecessary waste and need forhandling scrap. The prior art means and method is not sufficientlyflexible and does not provide for ready rearrangement or change inassembled crates required to meet the needs of changing specifications,assembly operations or other changing conditions and the number of pairsof cavities in individual crates is fixed thereby causing insufficientflexibility and requiring an inventory greater than actually used ofcrates and types of crates to be on hand and sometimes use of crateswhich are not adapted to a particular project.

The present invention overcomes the above-enumerated and otherdisadvantages of the prior art and provides additional advantages.

SUMMARY OF THE INVENTION The apparatus of the invention comprises a rackand a predetermined plurality of wire holding and dispensing moduleswhich the rack is structured to hold in a desired array, preferably inrow-by-row rearwardly upward stepped cascaded relationship. Each modulecomprises an open-ended box, which may be of elongated substantiallyrectangular cross-sectional shape, and an elongated flat, generallyrectangular-shaped divider. The box may further comprise means toremovably retain the divider, for example, slidable means.

The divider in box inserted position partitions the box into chambers.When loaded and in box inserted position, the wires dispensed on thedivider may be bifurcated, one end being in each chamber and the bightor bend apex being at the front of the divider. The divider may havewire bight retaining means at the front. For example, the divider frontmay be grooved. The upper chamber defining box sides may be bevelled tofacilitate operator grasping of individual wire bights in pulling outwires for use in assembling a unit of apparatus. Identification tabholding or marking means may be provided at the top front of eachmodule. In one embodiment, advantageous for wires longer than abouttwice the divider length, the divider is of flexible or resilientmaterial and its rear portion is looped downwardly and forwardlyterminating in a tongue. The box is slotted at the bottom to retain thetongue in divider locked condition. The loop is wider than the depth ofthe lower box chamber. The resilient material loop is contractable to athickness less than lower box chamber depth by medium pressure exertedby the operators thumb and forefinger. This enables the operator topinch the divider rear out of the tongue engagement in the slot when thedivider is pulled out of the box or to compress the loop when thedivider is slid into the box in tongue and slot locked engagement. Inanother embodiment, suitable for shorter wires, the divider mayterminate in a box rear end cover having U-shaped spaced walls sized tointerfit in the box inner walls and a flat end member sized to form aflange against which the rear box walls abut in divider retaining lockedposition.

In the inventive method, the assembler unlocks or disengages a dividerfrom a box enclosing one, sliding the divider rearwardly out of the box.The assembler selects a group to be boxed, e.g., one of the types in thewire kit" to be assembled into an equipment. The assembler then drawsthe group of wires, with one wire end held from the divider rearunderside, along the underside of the divider, and bends the group ofwires over the wire holding means (groove) at the front end of thedivider to form a bight. The assembler then draws the remainder of thelength of the group of wires along the top side of the divider.Utilizing the above-mentioned first embodiment divider having the loop,where there is wire remaining to do so, the remaining wire is dangledover the rear bent over portion of the loop and allowed to hangdownwardly. The divider is then reassembled into the tube with the wiresinserted by pinching the loop and at the same time sliding with thegrooved section forwardly disposed, from the box rear to the box frontuntil the tongue is aligned with the groove. Locking is then effected byreleasing the loop allowing the tongue to be depressed into the boxslot. This group of wires is then ready for assembly. The wire groupfilled boxes required for a given assembly or subassembly are positionedin stepped row cascaded position in desired arrangement either as tilledor later. Assembly ofa unit or units may then be effected. Due to thestepped and cascaded arranging of boxes, the long wires will dangle overthe rear divider loops, each row of wire ends resting on the loopdangling in a different plane.

The present invention provides the advantage ofelimination of twohandling operations. By employing the wire storage and dispensing boxesof the invention at the preparation station the prepared wires may beloaded into the individual boxes by groups and the loaded wires are thenready to be used in assembly operations thereby eliminating the bagpacking and the assembly into the egg crates operations of the priorart. Since the invention enables loading of one box at a time, thehandling of boxes of wires is not required as in the case of the priorart egg crate assembly where done at the preparation station.

In the invention, the wire storing and dispensing boxes are stored inthe rack in staggered array. Since the boxes may be made of equallengths, the wires which are long enough to require positioning over theloop in the first above-enw merated embodiment may dangle behind therack in different planes for different rows, thereby avoidingentanglement. Additionally, unless otherwise intended by the assembler,no more than one of the two ends will dangle over the divider rear endloop. Therefore, only one-half of the number of dangling wire ends for agiven number of long wires are necessary as contrasted with handling oflong wires in the egg crate prior art means.

In the prior art, the stuffing of groups of wires which were bent forassembly use had to be done by bending and forcing the unbent leg wirelength down each cavity of pairs of egg crate cavities. This madebending and warping of the wire portions within the cavity almostinevitable. In the present invention, the divider around which the wireis to be bent is first withdrawn from the box and a group of wires aredrawn from the divider rear along the underside, around the dividerfront and along the divider top. This wire drawing or pulling operationprovided by the invention overcomes the difficulty of having to push thewires and the deleterious effect on the wires.

The modular nature of the assembly of wire holding boxes and the rackstructure of the invention enables individual or several boxes to bedisassembled or assembled in the rack readily without affecting theremainder of the assembled structure. This is advantageous where a groupof wires is outmoded and a different group should be substituted. Thedifferent group of wires may be substituted in a box divider and thedivider readily assembled back into the module or box. The arrangementor order of the individual wire holding modules may be changed. Modulesmay be inserted, may replace modules as a substitute or some of themodules may be removed, thereby facilitating changes in assemblycorresponding to resequencing of assembly operations or redesign of thedevices to be assembled.

In one embodiment, rack expansion or contraction of the rows of wirestorage and dispensing modules may be more readily effected due tointerfitting adjustability of the rack cover member. This isadvantageous over the prior art egg crate wherein only a fixed number ofthe cavities provided may be used and the remainder left empty andunused. The invention provides better utilization and enables a lessernumber of wire storage and dispensing boxes to be stocked. Also thisadjustable interfitting rack and cover of the invention enables lessbulk at an assembly station where less than the total number of modulesassemblable into a rack need to be em ployed.

Accordingly, an object of the invention is to provide an improvedapparatus and method to store, package, and handle component wires forassembly into fabricated units wherein handling is facilitated, and theelimination or reduction of handling operations in preparation,dispatching and assembly stations is provided.

Another object of the invention is to provide a wire storage anddispensing station and method for assembly of electronic,electromechanical, and mechanical units and devices which will enable ahigher rate of available wires to be used for as sembly, which willlessen wire waste and scrap, wherein the wires are laid on and drawninto storage and dispensing module chambers wherein groups of ends oflong wires may be dangled behind the station in separate planes, whereina lesser number of wire storage and dispensing modules will be required,and which will facilitate handling of wires prior to and at assembly.

Another object of the invention is to provide an improved assemblystation comprising an improved rack and wire storage and dispensingmodular structure wherein ready rearrangement, adding to, subtractingfrom and/or substitution of modules in accordance with adjusting forchanges in technical plans at any time prior to or during the electronicunit assembly process is facilitated, and wherein expansion orcontraction of the number or types of wires utilized is facilitated.

Another object of the invention is to provide a means and a method forstorage and dispensing of wires wherein the number of usable wires isincreased and scrap reduced, facility is provided in handling, readyadaptability to changes in design or assembly of the wires into devicesis enabled, wherein drawing of the wire to avoid damage to individua.wires by twisting or pushing at storage and at assembly is avoided toprevent wire entanglement, and wherein the number of dangling wires andfrequency of possibility of intermingling of wires to provide unwantedentangling is avoided.

BRIEF DESCRIPTION OF THE DRAWINGS The above-mentioned and other featuresand objects will be apparent by reference to the following descriptiontaken in conjunction with the accompanying drawings in which:

H6. 1 is a view in perspective, as viewed by an operator from the leftside at the front, of a first preferred illustrative embodiment of thewire dispensing and storing module of the invention showing an unloadedfirst preferred illustrative embodiment divider and box, the dividerbeing inserted in locked position within the box, portions of the boxbeing cut away for clarity of illustration;

FIG. 2 is a view in opposite perspective, as viewed from the right rearside by an operator, of the first preferred illustrative embodiment wirestoring and dispensing module box of FIG. I with portions cut away forclarity of illustration and showing a rectangular, open-endedconfiguration terminated at one end by a bevelled portion to facilitatewire removal and a tab for facilitating stacking and at the other end ofthis view illustrating divider engaging rails and the bottom wall slotof the divider locking means;

FIG. 3 is a perspective view, as also viewed from the right rear side byan operator, of the first preferred illustrative embodiment wire storingand dispensing module divider of FIG. I, the divider being disengagedfrom the box and ready for mounting thereon of a group of componentwires, and showing a wire apex retaining groove, a rear loop over whichone end of long wires may be dangled, and a spring locking means; and awire section supporting means, the divider being shown in position to beassembled into the box of FIG. 2;

FIG. 4 illustrates a second preferred illustrative embodi merit of thewire storing and dispensing module divider of the invention also havinga wire apex receiving groove but terminating at the rear end, viewed tothe right, in a box closure, this divider being adaptable for storingand dispensing wires which are shorter than or equal to the both sidetotal length of the wire containing portion of the divider and whereinthe wire storage and dispensing module box may be similar to that ofFIG. 1 but preferably having an unslotted bottom wall;

FIG. 5 is an exploded view in perspective ofa first preferredillustrative embodiment of the assembly station of the present inventionshowing a first preferred illustrative embodiment of the rack of theinvention with a cover member shown in full lines removed from the rackand in phantom being dropped to assembled position in the rack ready tobe positioned in module array covering position and further showing arow of wire storage and dispensing boxes of the invention illustrated asloaded in the rack;

FIG. 6 is a view of an assembly station of the invention showing a sideelevational view of the preferred embodiment rack of FIG. 5 but having astack of modules mounted thereon comprising dividers of the embodimentof FIG. 3 loaded with wire components and locked in position in boxessuch as shown in FIGS. 1 and 2, the rack cover being installed in thestation in readiness for an apparatus assembly operation;

FIG. 7 is a view in perspective ofa second preferred illustrariveembodiment of the assembly station of the present invention illustratinga second preferred illustrative embodiment rack having an integral framecover portion and illustrating a plurality of the boxes of the modulesof the invention stacked in rows; and

FIGS. 8, 9 and [0 illustrate sequential steps of the method of theinvention in mounting a group of wires on the divider, inserting thedivider partially into the box, the divider then being positioned forretention in the box to form a loaded wire storage and dispensingmodule, the FIG. l module being shown for purposes of illustration, themodule then being stacked or emplaced in desired position in the arrayin the rack as illustrated in FIGS. 5, 6 and 7.

Refer to FIGS. 1, 2 and 3. A wire storing and dispensing module 200 (seeFIG. 3) which may comprise a box and a divider may be provided. Theportion of the box 20 and of the divider 25 to the left as viewed inFIGS. 2 and 3. is nearest the assembly operator when removing wires forinstallation into equipments, and is designated the front and theportion to the right is designated the rear. Box 20 may be generallyrectangular in longitudinal and in transverse cross section and maycomprise sidewalls 2i and 22, a bottom wall 27 and a top wall 31. Box 20may be made of a rigid metal or plastic. Divider 25 may comprise a frontto rear extending elongated flat plate portion 39 generally rectangularin longitudinal and in transverse cross section and having a wire apexretaining front located groove 34 formed or machined in the generalshape of a circular segment extending with the widest portion disposedtoward the front and extending for the major portion of the dividerwidth, a curved rear loop 35, a reversely bent angularly depending flatcompressible spring section 36 which, when free from transversecompression by an operator, is bent angularly outward from flat portion39 and a tongue 37 bent downwardly substantially normal to reverselybent section 36. Divider 25 may be formed of a rigid resilient materialsuch that loop 35 and the bent over portion 36 will have spring likecharacteristics to enable withdrawing the tongue 37 from the slot 26 bycompressing the loop 35. The material is rigid such that the wires maybe mounted thereon without deforming the box 20 in assembling foroperation. While nowise to be restricted thereto, one suitable materialis polyvinyl chloride (PVC), a thermal plastic which has retentivememory such that upon forming when hot, the divider tends to be restoredto original shape, that is, it is highly elastic. The tongue 37 extendssubstantially parallel to the loop 35 and is angularly bent outwardlywith respect to the bottom side 82 of the divider 25 in order to imparta positive spring pressure like that of a hair pin to give positivepressure locking at tongue 37 into slot 26. Spring member 36 mayalternatively be bent in the form of a slight ripple or wave (not shown)to provide additional elasticity. Divider 25 is of width slightly lessthan the distance between the inner surface of the side walls 21 and 22.Each of the sidewalls 2i and 22 may have formed thereon, integrally orotherwise attached, a pair of spaced protruberances or rails 23 and 24.The facing edges of rails 23 and 24 are separated slightly more than thethickness of divider 25 to slidably support or retain divider 25.Transversely formed or machined through the bottom wall 27 at the rearis slot 26.

Refer to FIG. 1. At the front end, shown to the right in FIG. 1, of box20 of module 200, the upper sidewall 21 and 22 may be chamfered bychamfers 28 and 29 extending downwardly to the bottom side rails 24 atfront terminations 43 and 44. A section of the top wall 31 is removed ortop wall 3l is formed shorter than bottom wall 27 to provide recedededge 70 set back from the front edge 127 of bottom wall 27 to terminatethe top of the bevels or chamfers 28 and 29. An identification tab 32may be provided. identification tab 32 may be flat, plate-shaped andrectangular in cross section and may be positioned about two-thirds ofits width edges on the upper ends of the inclined chamfered surfaces 28and 29 with the remaining width contiguous to and protruding above topwall 31. A cloth or paper marker 33 may be temporarily adhesivelysecured to tab 32 and may be marked with the identification of a groupof wires temporarily stored or to be stored on the box 20 containedslidably divider 25. Groove 34 ofthe slidable divider 25 may comprise aflat recessed rear surface (not numbered) which is curved forwardly atthe sides short of the side edges to form forwardly extending legs 41and 42, the groove 34 being somewhat in the shape of a centrallyflattened segment ofa circle. The divider 25 is made of width dimensionslightly less than the distance between the walls 21 and 22 to enabledivider 25 to easily slide within the rails 23 and 24 of wall 2i andwall 22 throughout the length of the rectangular box or tube 20. Theterms tube and box as used herein each mean an elongated open endedhousing which may be square, rectangular, circular or otherwise shapedin cross section throughout most of its length. The length of the flatportion 39 of the divider member 25 may be longer than the length of box20. When divider 25 is locked within box 20, the flat portion 39 may bethrust into the box 20 a distance such that the front projections 41 and42 are substantially contiguous with the front faces of the bevels 28and 29 at their side rail front ter minations 43 and 44. The lockedposition of divider 25 within box 20 is reached when the tongue 37 isopposite the groove 26. The lengths and physical orientations of theflat spring 36 and of the loop 35 with relation to the length of theflat portion 39, including forward projections 41 and 42, of divider 25are of appropriate dimensions to establish a divider 25 and a box 20longitudinally aligned relationship wherein in assembled conditiontongue 37 is depressed to engaged position in slot 26 and theforwardmost extended portion of the projection 4] and 42 issubstantially contiguous with the side rail front terminations 43 and44.

Refer to FIG. 4. A second preferred embodiment divider 65 is provided.Divider 65 may comprise a box terminating cover or box enclosure 75 anda front to rear extending elongated flat plate portion 66 generallyrectangular in longitudinal and transverse cross section having a frontgroove 74 which may be disposed and shaped similar to groove 34 of theFIG. 2 embodiment. The divider 65 may be placed into a box 20 dividerdimensioned to receive it but preferably a box 120 (see FIG. 7) nothaving a slot but otherwise similar in configuration to box 20 may beprovided. Divider 65 is suitable for storing wires wherein the maximumamount of the length of the wire does not exceed approximately twice thelength from the bottom of groove 74 to the inner bottoming surface 179of the divider end closure 75. While the invention is nowise to berestricted by this exemplified dimension, a 14-inch long container 20 or120 and a divider 25 or 65 of according dimensions meets manyrequirements for housing wires of lengths suitable for all or a portionof many power harnesses of electronie equipments. For the longer lengthof wire, the open ended top chamber version such as that employing thedivider 25 is desirable.

In flat slidable partition or divider 65 the front groove 74 is definedby a substantially flat bottomed curved portion (not numbered)substantially shaped as a segment of a circle the chord of which isalmost the full width of divider 65 and a pair of projecting fingers 71and 72 similar to the projecting fingers 41 and 42 respectively of theFIG. 3 embodiment. Similarly to flat plate portion 39 of the FIG. 3embodiment, the flat plate portion 66 of FIG. 4 is dimensioned toslidably fit within the opposing rails 23, 24 of sidewalls 2] and 22 ofthe box 20 or corresponding side rails (not shown) of box 120. Boxenclosure 75 may comprise a rectangular base 79 and a pair of separatedgenerally U-shaped box interior engaging panel units 77. Each of panelunits 77 may comprise a connecting panel 76 and a pair of end panels 78.The U-shaped panel units 77 are of dimensions and positioned such thatthe connecting panels 76 and end panels 78 fit in slidable and bearinglyretained relationship within the upper, side and bottom walls 31, 21, 22and 27 at the rear end (not numbered) of the box 20 illustrated in FIG.1 or correspondingly within the walls at the rear of box 120. The rearend surface of the flat plate portion 66 may abut and may be permanentlyaffixed to the inner surface 179 of the base 79 by conventionalattachment such as adhesive, thermosetting or thermoplastic attachment.The panels 78 are spaced apart at their facing ends adjacent the ends offlat plate portion 66 to permit the rails 23 and 24 or correspondingrails of box 120 to fit therewithin to permit closure of the divider 65rear end into the box. The base 79 may be of cross-sectional dimensionsto extend beyond the box interior engaging panel units 77, that is theunderside of connecting panels 76 and end panels 78. The base 79 thusprovides a flange (not numbered) on its inside box closure surface. Theflange extends a distance sufficient to lock further sliding within thecontainer to thereby form flange stop means in conjunction with the endsof walls of the container or box 20 or 120 into which the divider 65 isinserted. The space between panels 78 permits the rear ends of the rails23 and 24 of box 20 or corresponding rails of box 120 to be receivedtherebetween and abut against the flange. Wires may be emplaced in oneof the bins partitioned by divider 65 if short enough, e.g., under l4inches. When the wires are too long for one bin and not long enough toextend more than the length of two bins, the wires may be drawn from theunderside of flat portion 66, around the bottom edge defining groove 74,and above the top of flat portion 66 and divider 65 may be employed tomount such wires for storing in a module box 120.

Refer to FIG. 5. The wire storage and dispensing station provided inthis embodiment of the invention may comprise a rack 100, a rack cover61, and a plurality of wire storing and dispensing modules 20 or 120.The rack 100 and cover 61 may be of frame construction and may be formedof rods or of tubes of desired cross-sectional configuration. The words,top, bottom, upper, lower, vertical, horizontal, side, left side, rightside, as used in the description of the rack 100 of FIGS. and 6 refer tothe view as illustrated in FIGS. 5 and 6 of the drawings. The rods ortubes of the rack and cover may be secured together by conventional wayssuch as by welding or spot welding, bolts or screws and nuts, rivets,etc.

In the rack there may be provided a first rear frame rod 45 and a doubleangularly bent side frame rod 49 disposed in a first vertical frame, asecond rear frame rod 46 and a double angularly bent side frame rod 50disposed in a second vertical plane spaced from the first vertical planeto define the rack 100 width, a U-shaped frame 18 comprising asupporting rod 53 and two side arm rods 51 and 52 and base frame rods91, 92, 93 and 94, which, as will be described may alternatively beseparately attached to the rear, side and U-shaped frame rods or mayform an integral, rectangular base frame, for example with the baseframe attached at its corners, for example to the rear, side andU-shaped frame rods. Double angularly bent frame rods 49 and 50 eachhave a first lower bend and a second upper bend. Rod 91 is disposedhorizontally across the front of rack 100. Rod 91 is connected at oneend to the side frame rod 39 at the lower bend. Rod 91 is connected atits other end to the side frame rod 50 at the lower bend. Rod 92 isdisposed horizontally extending from the front to the rear of the rackat right angles to rod 91. Rod 92 is connected at one end to the rearframe rod 46. Rod 92 is connected at the other end to the side frame rod50 at the lower bend. Rod 93 is disposed in the horizontal plane of andparallel to rod 92 and spaced therefrom. Rod 93 is connected at one endto the rear frame rod 45. Rod 93 is connected at the other end to theside frame rod 49 at the lower end. Rod 94 is disposed in the horizontalplane of rods 91, 92 and 93 across the rear of rack 100 parallel tofront rod 91. Rod 94 is connected at one end to the rear frame rod 45and at the other end to the rear frame rod 46. Front base rod 91, sidebase rods 92 and 93 and rear base rod 94 and the interconnectionsthereto from a rectangular base frame 40. A portion of the rear framerod 45 extends beneath the attachment to legs 93 and 94 and forms a racksupporting leg 145. A portion of the rear frame rod 46 extends beneaththe attachment to legs 92 and 94 and forms supporting leg I46. Securedon the bottom ends of legs and 146 there may be provided flexible cups47 upon which the rack legs 145 and 146 may be frictionally supported ona surface. Double angularly bent side frame rods 49 and 50 are each bentin the first direction vertically downwards perpendicular to the base 40to form respective leg 149 and leg 150 which may be of equal length tothat ofleg 145 and ofleg 146. Addi tional flexible cups 47 may also beprovided and secured upon the supporting ends of each of legs I49 and150. Additional flexible cups 47 may also be secured to the ends of sideframe rods 49 and 50 opposite respective legs 149 and 150. Cups 47 areof flexible material, rubber, for example, to protect the desk, bench orother surface upon which the rack 100 may rest and to provide a firmfrictional antislip footing. The side frame rods 49 and 50 each furthercomprises a respective angularly bent front frame side section 55 and56. Sections 55 and 56 each are disposed in the vertical plane and sloperearwardly and upwardly from the legs 149 and 150 and are bent atrespective second bends 57 and 58 to third angularly extending sideframe rod sections 59 and 60 respectively. Sections 59 and 60 extendsubstantially in the horizontal plane. Horizontal sections 59 and 60 areconnected near but not at their ends to vertically extending rear framerods 45 and 46. Side frame rods 59 and 60 extend horizontally rearwardlybeyond rear frame rods 45 and 46 to form side rod legs 159 and 160. Rodleg 159 and rod 160 may each terminate in an additional flexible cup147. Side rod legs 159 and 160 extend rearwardly beyond the rear baseside 94 of the frame 40. The U- -shaped frame structure 18 side holdingrods 51 and 52 are angularly sloped rearwardly upwards in the verticalplane at the angle that the front frame side sections 55 and 56 aresloped rearwardly upwards. Rod 51 is attached at its end opposite thatconnected to rod 53 at a point rearwardly disposed from the front to therear along side frame rod section 59. Rod 52 is attached at its endopposite that connected to rod 53 at a point equally rearwardly disposedfrom the front to the rear along side frame rod section 60. The U-shapedstructure 18 may be secured at the junction between the intermediatebase support rod 53 and the side holding rod 52 to the leg 92 at a pointapproximately halfway from the front to the rear of leg 92. The junctionbetween the rods 51 and 53 may be secured at a corresponding point ofleg 93 from the front of the leg 93 toward the back.

Cover 61 is structured to adjustably retain boxes 20 or 120 in tightlyheld or compressedly secured relationship within the rack 100. The framecover 61 may be generally rectangular in shape and may comprise a firstU-shaped frame comprising a pair of end box retaining rods 63 and 64, arear box retaining rod 62, and may further comprise a closing U-shapedfront box array retainer 162 parallel to rod 62 and secured to the endsof rods 63 and 64 to fonn the fourth side of rectangular frame cover 61.Box array retainer 162 may comprise a straight front top cover rodsection 165 in the approximately same horizontal plane and parallel torod 62 and may further comprise short vertically upward bent front frameside section engagers or cover retainers 163 and 164 at each end. Coverretainers 163 and 164 are spaced by rod 165 to closely and preferablybearingly engage the outer facing edges just outside of rods sections 55and 56. This spacing and the structure of cover 61 enables rod 165 andhence cover 61 to be slidably mounted upon and be adjustably positionedon or be slid downwardly forwards along the side frame rod sections 55and 56. The slidable retaining projections 163 and 164 enclose theangular rod sections 55 and 56. The uppermost position from which thecover is rested on or is slid downwardly depending upon the position ofthe upper walls 31 of the top row of boxes 20 is shown in phantom atlocking engagement bends 57 and 58. The cover structure and spacingthereby provide a cam column compressing feature to retain the modulesfirmly but removably between the base and cover of the rack.

End box retaining rods 63 and 64 of cover frame 61 may be attached nearthe ends of front top cover rod section 165 at points opposite ends ofrod 62. The spacing and dimensioning may be made such that rods 63 and64 fit snugly within the side frame rods 49 and 50 within the arm or boxside holding rods 51 and 52 such that the cover 61 may be positionedalong sections 55 and 56 to rest upon the top surface of walls 31 of theboxes 20 or 120 stacked in rack 100. Shown in dashed lines in FIG. arethe boxes or 120 aligned in the lowermost row of an array or matrix ofboxes. The front ends of the lowermost row of boxes 20 or 120 rest upontheir lower wall 27 or the corresponding box 120 lower wall undersurfaces near its front, on the front base rod 91. The lower walls 27 orcorresponding walls of the boxes 120 of the lowermost row of boxes 20 or120 rest upon the intermediate base support rod 53 of the U-shaped rearsupport 18. The width of the rack 100 between the side frame rods 49 and50 and the widths of the modules are in interrelationship such that apredetermined number of modules, 200 per row, may be disposed betweenthe frames 49 and 50 in tightly held frictionally nonreadily modulemovable engagement. The rack boxes are preferably made of material suchas polyvinyl to impart elasticity when compressed and the surface issuch as to present some friction to non intended sliding between thesurfaces of adjacent boxes 20.

It will be understood that either boxes 20 or 120 or corn binationsthereof or other boxes in accordance with the invention may be stackedin the rack of FIGS. 5. 6 and 7. The description of FIGS. 5 and 6mentions boxes 20 and its elements by way ofexample and is to beconsidered as applicable to and to include a description, emitted forbrevity and clarity, of the boxes 120 and corresponding elements orother embodiments which may occur. The description of Fit]. 7 alsomentions boxes 120 and its elements by way of example and is consideredto be applicable and include also a description of the boxes 20 andcorresponding elements, etc.

Refer to FIG. 6. Stacking is effected in an upwardly rearward steppedarrangement of rows of wire boxes 20 (or boxes 120). This is done bystacking each box 20 of each row except the bottom row such that theforward edge 127 of the bottom wall 27 of each such box 20 abuts therear edge 30 of the identification tab 32 of the box 20 stackedimmediately below. The box 20 front bottom edge 127 may be jammed orlightly wedged under the tab 32 at the niche 129. The material andsecuring of the tab 32 are made flexible and permit yielding such thatsome frictional and/or wedged holding together of boxes 20 is effected.This abutting and wedging affords the desired stepping angle and retainsthe boxes 20 in desired array with a locking feature afforded becauseforce is necessary to overcome friction and to pry apart stacked andslightly wedged box edges 127 from the rear tab edge 30 and niche 129defining sides comprising top wall 31 and the rear side 30 of tab 32.This enables and/or facilitates holding together in desired array of theboxes 20 whether standing as shown in FIGS. 5, 6 and 7 or resting on therear in box front edge 127 upwardly facing array. The rack hasadditional versatility in that it may be either upended or placed on thebench or rack support (not shown) in the position shown in FIGS. 5, 6and 7 so that access either from the front or from the top of the rack100 may be had during assembly of wires into equipment by the operator.The rack 100 when in rack front upended position stands at a slightangle from the vertical resting upon the rear cups 147 and substantiallytangential to the rack supporting surface upon side edge points of cups47 of rack supporting legs and 146.

The angle with respect to the vertical plane of the side frame rodsections 49 and 50 is preferably approximately the angle by which theboxes 20 are stepped in upwardly receding relationship as the rows arestacked. With the stacking in rack 100 of wire containers or modules thewires extending over the edge of the loops 35 will dangle downwardly ina successively receding plane for each row progressively upward in thecolumn of rows such that entanglement of wires in the rear is reduced oravoided. This feature is illustrated at the right of FIG. 6 showing therear of the therein illustrated modules 20. The feature of stepped rearterminations is unnecessary for rear enclosed boxes 120 and dividers 65.

The stepped array of boxes enables the operator, who is at the front ofrack 100, shown to the left in FIG. 6 to have better access to the work.Access by the operator is also facilitated by the box front chamfers orbevels 28 and 29 in box 20. The inclined from upper chamber surface notonly enhances accessibility by the fingers of the human hand of theoperator. but better protects the operators fingers in reaching at assembly for wires.

The cover member 61 may be positioned along the inclined sections 55 and56 of rods 49 and 50 downwardly and forwardly to a position where cover61 rests upon the top row of the stacked boxes 20.

As seen by the dashed lines in the exploded view of FIG. 5, the cover 61is readily removable. This permits ready removal of any one of the boxes20 in the array of columns and rows, which box 20 is to be eitherdeleted or substituted for or wherein a change of wire or of assemblysequence has been determined to be made. In that way, a change inaccordance with desired design change of the device to be assembled orin accordance with manufacturing needs may more readily be made due tothe modular construction of the wire storing and dispensing modules anddue to the rack of the invention.

The spacing of the front box array retainer 162, front rod section andprojections 163 and 164 in conjunction with the dimensions andconstruction of the end box retaining rods 63 and 64 and rear rod 62,frame rods 49 and 50, and base support 18 facilitates positioning andpermits additional sliding adjustability in emplacing the cover 61 toclampingly engage the boxes 20 at the upper walls 31 of the upper row.

Refer to FIG. 7. in this embodiment of the assembly station of theinvention there may be provided a multipositionable fixed height rack110 having an integral cover 111. Alternative use in the horizontal orvertical plane is provided. Cover 111 serves as a front member inupended position of the rack. The rack 110 and cover 111 may be formedof frame rods or tubes of any of various desired cross'sectional shapes.A side frame 140 and an opposite side frame (not shown) are provided.Each of the side frames 140 may have a long base side frame rod 142, arear support rod 246, and a front double an gled side frame retainingrod 160. Front double-angled side frame retaining rod 160 may have acover box retaining section 163 which extends horizontally rearward froman upper bend 158 at the rack upper front. From bend I58, rod 160 isbent to form a forwardly and downwardly extending angled side section155. A second lower bend 157 is made in rod 160 at the lower end ofsection 155 to provide a vertical supporting leg section 150. Asindicated hereinabove, boxes 20, 120 or other boxes and modules inaccordance with the invention may be stacked in rack 110, boxes I20being referred to by way of example. Base frame rods (not shown) supportthe bottom wall (not numbered) of the row of boxes 120 stacked in therack 110. One of the base frame bottom box supporting rods (not shown)may be disposed underneath the lowermost row of boxes 120 near the frontand may extend from the junction between the side frame rod 160 and thelong base side frame rod 142 to the opposite corresponding junction ofthe opposite long base side frame and side frame rods (not shown). Theother supporting frame rod (not shown) is disposed near the rear of andunder the boxes of the bottom row to support the rows of boxes and maybe connected between the rod 142 and its opposite rod (not shown). Therear support rod 246 may extend below the long base side frame rod 142to form a supporting leg section I46. Leg sections I46 and 150 arepreferably the same length. The long base side frame rod may extendrearwardly of rear support rod 246 to form a supporting leg section 245.beg sections 146 and 245 are perpendicular. The short base side framerod 163 also may extend rearwardly of rear support rod 246 a distancepreferably equal to the height of the leg section 245 to form a legsection 161. The supporting leg sections 146, 150, 161 and 245 and thecorresponding leg sections on the opposite side frame (not shown) eachmay be provided with fitted on flexible supports or cups 242. Cups 242may be similar to and provide the functions of cups 47 and 147 of FIGS.5 and 6.

The leg sections 146 and 150 and corresponding leg sections (not shown)on the opposite side enable the rack 110 to be supported in the positionshown in FIG. 7. Alternatively, the legs 16] and 245 and correspondinglegs of the opposite side may support the rack 110 in upendedperpendicular position with the boxes I disposed vertically with thefront (shown to the right in FIG. 7), then being in the position openingfrom the top. This is achieved by rotating the rack 110 counterclockwise90 from the position illustrated adjacent the legend FIG. 7 of thedrawings.

As shown in FIG. 7, the boxes 120 may be stacked in the rack 110 in rowsand in stacking progressively upward may be stepped backwards. In eachcase the front edge of the bottom side of the box 120 is abutted againstthe rear edge of the identification tab (not numbered) of the nexthigher row box identification tab 32. This forms a stepped back nestedarray which preferably follows along the angle to the vertical of thefront angled side frame retaining rod 160. The nesting facilitates therack 110 functions wherein it serves as both a guide and to frictionallyhold the nested rows of boxes together in the desired array in bothhorizontal and vertically disposed positions of the rack 110. The rackand module relative dimensions are preferably such that with a fullyloaded complement of boxes 20 or 120 the pressure of the rack 110 crossbar 265 and the corresponding top rack cover 61 of the FIGS. 3 and 4embodiment enables compressing the boxes 120 from top to bottom so as toreleasably retain the boxes within the rack under retaining pressure.

Refer again to FIGS. 1-3 inclusive and refer to FIGS. 8 I0 inclusive.Straight portion 39 of divider has an under surface 82 and a top surface83. A plurality of prepared wires 81 of a predetermined type may beprovided at the preparing station sufficient in number to assemble a joborder or a predetermined number of units to be manufactured. To commencethe loading operation the operator obtains a wire storing and dispensingmodule divider 25 from its storage place either with other dividers 25or form within a wire storage and dispensing module 200 which isunloaded. Refer to FIG. I. An unloaded divider 25 may be stored in thebox 20 of a module 200. The outside surface 38 of spring section 36 maybe grasped by the thumb and the approximately opposite upper surface 83of straight portion 39 may be grasped by one or more of the index,second and third fingers, for example, as comfortable or more efiicient.Alternatively, the module 200 may be turned upside down and with thethumb engaging the upper surface 83, the surface 38 may be grasped byanother finger or fingers. Grasping is effected with sufficient force tocompress the spring section 36 toward straight portion 39 until thetongue 37 clears the slot 26. This pressure may be continued and thedivider 25 may be withdrawn under this pressure rearwardly out of thebox 20 of module 200. Alternatively divider 25 may be rearwardlywithdrawn until the tongue 37 is beyond the rear of the slot 26 and thepressure then slackened with tongue 37 being slid along the bottom wall27 until it clears the rear edge 48. Upon closing rear edge 48 thepressure may be further slackened to only enough grasping pressure sothat the divider 25 may be withdrawn from box 20.

Refer to FIGS. 8 and 9. Prepared wires 81 may be positioned at the wirepreparing station on the divider 25 with one end resting in the loop 80.Human fingers or a releasable clamp (not shown) may hold this end ofwires 81 in position in loop 80. The remaining length of the wires 81are drawn or wrapped along the divider undersurface 82 from the loop 80,then folded around the front of the groove 34 between fingers 41 and 42,then to extend over the upper side 83 and over the curved rear loop 35to dangle downwardly thereover. The wires 81 form a bight or apex 86 atthe folded and nested position in groove 34. While nowise to be limitedto a particular number, by way of example, 35 wires of a particular typemay be mounted upon the wire loaded divider 25. FIG. 9 illustrates, thewires 81 in mounted position on divider 25.

The front or grooved end (not numbered) of the divider and wire holdingmember 25 is then aligned with the rear face (not numbered) of the box20 and positioned in a plane between the rails 23 and 24 protruding fromthe sidewalls 21 and 22. The divider 25, with the apex or bight 86 ofthe group of wires 81 held within the groove 34, is then slid forwardlywithin and between the rails 23 and 24 to the position illustrated inFIG. 10. At approximately this position of the divider 25 the tongue 37and flat compressible spring section 36 are elevated with relation tothe underside 82 of the divider 25 by squeezing the compressible flatspring section 36 and the rear end of the upper side 83 of the flatportion 39 between the thumb and index holding other finger(s) of theoperator's hand, such that the tongue 37 clears the lower wall 27. Thedivider 25 is slid further forward within the box 20 until the tongue 37has been positioned opposite the groove 26 in the bottom wall 27 of themodule box 20. In this position, the tongue 37 is released and anyrequired sight late and/or longitudinal adjustment of the divider 25position is made until the spring action from the restoring force urgingspring 36 downward causes the tongue 37 to be depressed into the slot 26as illustrated in FIG. I. Upon depression to engage the tongue 37 intoslot 26 the divider 25 is fixedly engaged within the box 20 in positionfor the wire assembly operation required for manufacturing a unit to bebuilt. With the divider 25 locked into place, or at any other convenienttime, the box 20 may be labeled for example, by attaching a cloth orpaper adhesively backed appropriately marked marker 33 to theidentification tab 32. The designation on marker 33 may, for example,characterize the particular wires 81 of identical characteristics suchas particular lengths and types to be mounted upon a divider 25 andemplaced in box 20 of a particular wire dispensing and storing module200 for later assembly into electronic or other units.

Refer to FIGS. 5, 6 and 7. Prior to assembly of equipment units. aplurality of loaded wire dispensing and storing modules 200 comprisingboxes 20 and inserted dividers 25 each containing its complement ofwires such as wires 81 mounted thereon are stacked, into the rack 100 or110. Stacking may optionally be done sequentially as the modules 200 areloaded in desired row and column positions to facilitate the assemblyprocess. Alternatively, a complement of modules 200 may be loaded withthe wires of the groups to make up the required number of powerharnesses and the modules then stacked in desired positions in the rack100 or 1 10.

In the FIG. 3 divider, as shown in H6. 6, 9 and 10, the portions ofwires 81 extending beyond the top surface 83 section opposite the loop80 contained ends dangle behind and downwardly along the outside of loop35 and therebelow in a plane behind the rack or 110. Thus a maximum ofonehalf of the wires ends (one end for each wire) dangles behind a wireloaded module 200 in substantially a single vertical plane. The modules200 are loaded in the rack 100 or 110 by having successively upward rowsof boxes stepped by dint of positioning each upper row box front 127 ofbottom wall 27 against the back of the next lower row correspondingcolumnar positioned box identification tab 32. This provides the steppedarrangement illustrated in FIG. 6 wherein the ends of wires 81 in themodule 200 upper chamber (not numbered) of each row above the lowest rowdangle in substantially a single plane receded from the plane ofdangling wire 81 ends in the row therebelow. The lowest row overhangingends of wires 81 dangle in the frontmost plane of dangling wire planes.

The method steps of the invention of drawing of the wire around thedivider instead of pushing of the wire ends into the front end of wirereceiving chambers minimizes or reduces twisting or bending of the wireprior to unit assembly. By pulling the wire from the inner portion ofthe space 80 along the flat undersurface 82, over the groove 34 andalong the top side 83 of dividers 25 and dangling the ends over loop 35wire twisting is reduced or minimized. Less or minimum wire entanglementis caused in loading and assembling modules in accordance with theinvention due to the stepped alignment of rows of modules 200 such thatoverhanging ends of different rows of wires 81 overhang in separateplanes. The features that at most only one-half of the wire ends dangle,the wire drawing rather than wire pushing in wire storage and dispensingbin or chamber loading, and the resultant lack of twisting and bendingof the wires, enable the individual wires 8! to be more readily pulledfrom the front of each of the modules in the assembly operation. In theassembly of units, one of the divider 25 or 65 mounted wires 8! isgrasped between the fingers of the operator at the apex or bight 86. Theoperator may optionally hold the remaining wires 81 in place. By virtueof the relative freedom of disentanglement afforded by the invention,one wire 81 may be readily separated from the others by the operator. Asseparated from the others, each wire 81 is installed in a predeterminedposition in the unit being assembled. The rack and box structure and themethod of the invention facilitate installation at a bench where therack is supported.

The invention thereby provides a means and a method whereby storage,packaging and handling of wire for assembly operations is facilitated,packaging and handling of wire for assembly operations is facilitated,elimination of handling operations in preparation, dispatching andassembly stations results, greater amounts of productive use of preparedwires is enabled and scrap reduced, the assembly of units of equipmentis facilitated, the wires assembled into equipment are kept in betterand less stressed and strained conditions and whereby the rackconstruction and the modular construction of wire containers enablesready rearrangement of modules, replacing of different modules, andadjusting for changes in equipment. The means and method of theinvention enables a reduction in handling time to load wires intocontainers. The containers of the invention may be utilized as acombined shipping and packaging unit after preparation of wires. Theinvention further improves product reliability and enables avoidingdamage to prepared ends of wires. The invention also provides for easieridentification of individual wires or types of wires. Assembly and/orstoring operations are facilitated by the invention since the racks maybe stored and/or may be utilized at assembly in either a horizontal or avertical position.

While salient features have been illustrated and described with respectto particular embodiments, it should be readily apparent thatmodifications can be made within the spirit and scope of the invention,and it is therefore not desired to limit the invention to the exactdetails shown and described.

What l claim is:

1. A modular wire storage and dispensing station to facilitate assemblyof units having wire components comprismg:

a. a rack, said rack further comprising:

l a support base, 2. a pair of said enclosures, and 3. a cover,

b. a plurality of wire storage and dispensing modules removablystackable between said side enclosures and between said base and saidcover of said rack, each of said modules further comprising:

1 an elongated box having an open front end,

2. a removable elongated wire supporting box divider contoured to fit inlongitudinally extending relationship within said box, said dividerhaving wire supporting and retaining means adapted to be loadable withand to retain wires in box removed condition, and

3. means to removably secure said divider in said box such that uponloading wires thereon said divider may be inserted into and retained insaid box to divide said box into chambers to temporarily store saidwires in position for removal through said box open front end; andwherein:

said rack support base and side enclosure are of frame construction,

. said modules are formed of elastic material and are of width withrelation to said side enclosures such that a predetermined number ofsaid modules are frictionally slidably contained in one of said rows,

said cover further comprises a cam interfitting means to compress saidmodules between said cover and said support base to clampingly securesaid modules therebetween in releasable engagement,

said cam interfitting means further comprises a substantially U-shapedcover front frame member having a straight frame section terminated ateach end by a cover retainer angularly bent with respect to saidstraight frame section,

. said side enclosures each further comprises:

1. a rear frame member having a normally vertically disposed leg,

2. a double angularly bent frame member having a normally horizontalupper side frame section and a normally rearwardly upward angled sideframe section,

. said side enclosures, said straight frame section and said coverretainers are relatively spaced and dimensioned such that said coverretainers are adjustably engageable with said side frame sections towhen positioned form said cam interfitting means to compress saidmodules between said cover and said support base in said releasableengagement, and

. said box of each of said modules further comprises:

1. a tab extending angularly vertically from said box to provide asurface against which a next vertically stackable module in said rackabuts to provide vertically stepped rows of said modules in said racksubstantially angularly following the direction of said rearwardlyupward angled frame section.

2. A modular wire storage and dispensing station to facilitate assemblyof units having wire components comprismg:

a. a rack, said rack further comprising:

1 a support base, 2. a pair of side enclosures, and

3. a cover,

a plurality of wire storage and dispensing modules removably stackablebetween said side enclosures and between said base and said cover ofsaid rack, each of said modules further comprising:

. an elongated box having an open front end,

2. a removable elongated wire supporting box divider contoured to fit inlongitudinally extending relationship within said box, said dividerhaving wire supporting and retaining means adapted to be loadable withand to retain wires in box removed condition, and

3. means to removably secure said divider in said box such that uponloading wires thereon said divider may be inserted into and retained insaid box to divide said box into chambers to temporarily store saidwires in position for removal through said box open front end,

c. said box, divider, and means to movably retain said divider furthercomprising:

d. a box top,

e. a box bottom,

f. an elongated flat plate divider section having a bottom surface, atop surface and a front surface defining a wire bight receiving grooveto enable drawing of said wire along said bottom surface. around saidfront groove defining surface and along said top surface for said wireloading and retaining,

g. a pair of rails protruding from the inside of each of an opposing twoof said top, bottom and sides, said rails being separated to form agroove therebetween,

h. said divider being of dimensions with relation to the spacing betweensaid opposing two insides and between said grooves to be slidablymovable within the rails to divide said box into chambers such that saiddivider may be removed for loading, loaded, and reinserted within saidbox, and

i. means to lock said divider into position within said box where saidfront wire bight receiving groove is accessible by human fingers fromsaid box front open end.

3. The modular wire storage and dispensing station of claim 2 wherein:

a. said box sides are forwardly downwardly chamfered from said top atthe front and said top terminates at the front rearwardly of said bottomat the front thereby facilitating human finger accessibility and visionfrom the front,

b. said rails comprise top rails and bottom rails protruding from saidbox sides,

c. said box has an open rear end,

d. said divider when inserted into said box extends beyond said box openrear end,

e. said divider has a reversely downwardly bent loop disposed at itsrear end to support wire ends extending thereover such that the wireends dangle substantially in a plane immediately to the rear of theplane defined by the rear surface of said loop, said means to lock saiddivider further comprises a compressible spring section formed ofelastic material and bent forwards from the lower end of said loop at anobtuse angle to said elongated divider section and bent substantiallyperpendicularly downwards at its forwardly terminating end to form atongue, the spacing between said spring section in uncompressedcondition and said elongated divider section being larger than thespacing between said bottom rails and said box bottom, said spring beingcompressible between human fingers such that said tongue clears said boxbottom when said elongated divider section is slid in the groove betweensaid top and bottom rails,

g. said box bottom has a slot rearwardly disposed, said tongue and saidslot are parallel and said tongue and said slot are dimensioned andpositioned to lockingly interfit when the divider is in operativeinserted wire storing and dispensing position,

h. said box has an identification tab angularly disposed to its axis andprotruding to enable rearwardly stepped stacking of superimposedmodules.

2 wherein:

a. said box sides are forwardly downwardly chamfered from said box topat the front and said top terminates at the front rearwardly of saidbottom at the front,

b. said rails comprise top rails and bottom rails protruding from saidbox sides,

c. said means to secure said divider further comprises:

1. a box rear end enclosable wall having a dimension greater than theinner side spacing of said box,

2. means to attach said box enclosable wall perpendicularly to said flatplate divider section,

3. a first and a second U-shaped wall spaced to receive said flatdivider section and the rear ends of said rails therebetween anddimensioned to bearingly slide within the rear top, bottom, and sideportion within said box.

5. 1n station means to store prepared wires and to assemble said wiresinto equipment, a wire storage and dispensing module comprising:

a. an elongated box having top, side, and bottom walls and having openfront and rear ends,

b. a box divider having supporting surfaces including a front surface toretain a wire bight and top and bottom supporting surfaces to supportwire bifurcated ends,

. means to slide said divider selectively into box inserted conditionwherein said wire bight retaining front surface is accessible from saidbox front end and said box is divided into wire end storing chambers, orto box removed condition to enable a wire to be drawn around saiddivider in bent wire configuration to fonn a bight and bifurcated endssuch that said wire bight is disposed at said divider front surface andsaid wire ends are disposed along said bifurcated end top and bottomsupporting surfaces,

d. means to secure said divider in said box in bight graspable position,

. said box front end sidewalls being bevelled downwardly and forwardlyfrom said top wall, and said bottom wall extending forwardly of said topwall, to facilitate vision and grasping of said bight, and wherein saidbox bottom wall has a slot near its rear wall end,

. said divider further comprises:

1. a substantially rectangular elongated flat plate having opposite sideedges and a rearwardly downwardly bent loop around which wires extendingbeyond said top surface are dangled,

2. a compressible material flat spring forwardly extending from thelower end of said loop to form an obtuse angle with said divider bottomsupporting surface with the spring forward end positioned in springuncompressed condition below said box bottom wall when said divider isaligned to be inserted into said box, and

3. A substantially downwardly extending tongue terminating said springand of dimensions to be engagingly received in said slot,

. said means to slide said divider further comprises a pair of railsinwardly protruding from each said sidewall of said box and spaced toreceive one of said side edges of said divider, said box inwardsidewalls being spaced to receive said divider between said oppositeside edges,

. said divider is of greater length than said box,

. said wire bight retaining front surface means further comprises a pairof forwardly extending fingers and a recessed center front sectiondefining a groove in which wire bights are disposed, and

k. said divider fingers at the forward end are substantially contiguouswith the adjacent box forward side edges when said tongue is engaged insaid slot such that said bights disposed in said front section grooveare in said bight graspable position.

6. A method of manufacturing a unit containing wires comprising thesteps of:

a. preparing groups of the wires;

b. placing in proximity respectively each of said groups of wires, andfor each of said groups a separable wire mountable box divider havingfirst and second surfaces and a front end, and a divider retainable boxhaving an open front end;

c, drawing the wires of each of said groups along said first surface,around said front end, and along said second surface of said grouprespective divider to form bights at the front end and bifurcated wiresections;

d. inserting each of said respective dividers into its said respectivebox to form therewith respective wire group storing and dispensingmodules each having a first and a second chamber and a wire bightaccessible open front; and

e. stacking said modules in a rack in rows comprising at least one row;

f. at least one of said dividers having a rear downwardly reversely bentloop, said drawing step further comprising:

g. positioning one end of the respective groups of wires of the at leastone downwardly reversely bent box divider within the loop;

h. retaining said one end within the loop while drawing said last-namedgroup of wires along said first surface, then around said front end, andthen along said second surface of said box dividers; and

. draping any of said last-named wires which are longer than the lengthof said combined first and second bifurcated wire sections along saidfirst and second surfaces and said bight, over said loop to danglesubstantially in a plane rearwardly of said loop.

7. The method of claim 6, said stacking step further comprising:

a. arranging said modules in upward progressively stepped back rows suchthat said longer wires of each said row of modules dangles in asubstantially separate plane.

8. A method of assembling a unit comprising the steps of:

a. preparing groups of wires at a wire preparing station,

b. mounting each of said groups at said preparing station upon a dividerhaving first and second surfaces, a grooved front end, and a reardownwardly bent loop, said mounting further comprising:

1. positioning one end of the wires of said group within the loop,

2. retaining said end within the loop and drawing said wires along saidfirst surface, around said grooved front end, along said second surfaceand any remaining wire length over said loop to form wire bightsadjacent said grooved front surface, bifurcated wire ends along saidsurfaces, and remaining wire ends dangling in a plane behind the loop,

. inserting said divider to box loaded position into an openended boxhaving a means to releasably receive said divider in loop protrudinglocked in relationship whereby said remaining wire lengths danglesubstantially in a plane rearwardly immediately beyond said loop, andsaid bights are accessible from the front by the fingers of a hand, andhaving an angled angularly protruding tab,

. stacking in predetermined array a plurality of said loaded boxes in arack in rows such that the end surfaces of the boxes of each row abovethe bottom row are stacked against one of the sides of the tabs ofcolumnarly corresponding boxes of the next vertically disposed row tothereby stack the boxes in stepped backward relationship such that theremaining wires lengths dangle in separate planes for each row', and

compressingly securing said loaded boxes in the rack The method of claim8 including:

selectively loading additional dividers into boxes, and deleting,inserting and rearranging said loaded boxes including said additionalloaded boxes in accordance with currently changed composition,characteristics and numbers of wires required for said unit.

10. The method ofclaim 8 including:

"M050 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent: No.3, 599, 800 Dated August 17, 1971 Inventor(s) Bernard J. Durante It iscertified that error appears in the above ide ntified atent and thatsaid Letters Patent are hereby corrected as shown below? Col. 1, line26, "bundles" should be -bundled. Col. 7, line 54, after "walls" insert2l, 22, 27 and 31 or corresponding ends of walls.

Col. 8, line 19, after "rod, "39" should be 49--. Col. 13, line 58,after "facilitated," delete "packaging and handling of wire for assemblyoperations is facilitated,".

Signed and sealed this uth day of April 1 972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOT'ISCHALK Attesting Officer Commissionerof Patents

1. A modular wire storage and dispensing station to facilitate assemblyof units having wire components comprising: a. a rack, said rack furthercomprising:
 1. a support base,
 2. a pair of said enclosures, and
 3. acover, b. a plurality of wire storage and dispensing modules removablystackable between said side enclosures and between said base and saidcover of said rack, each of said modules further comprising:
 1. anelongated box having an open front end,
 2. a removable elongated wiresupporting box divider contoured to fit in longitudinally extendingrelationship within said box, said divider having wire supporting andretaining means adapted to be loadable with and to retain wires in boxremoved condition, and
 3. means to removably secure said divider in saidbox such that upon loading wires thereon said divider may be insertedinto and retained in said box to divide said box into chambers totemporarily store said wires in position for removal through said boxopen front end; and wherein: c. said rack support base and sideenclosure are of frame construction, d. said modules are formed ofelastic material and are of width with relation to said side enclosuressuch that a predetermined number of said modules are frictionallyslidably contained in one of said rows, e. said cover further comprisesa cam interfitting means to compress said modules between said cover andsaid support base to clampingly secure said modules therebetween inreleasable engagement, f. said cam interfitting means further comprisesa substantially U-shaped cover front frame member having a straightframe section terminated at each end by a cover retainer angularly bentwith respect to said straight frame section, g. said side enclosureseach further comprises:
 1. a rear frame member having a normallyvertically disposed leg,
 2. a double angularly bent frame member havinga normally horizontal upper side frame section and a normally rearwardlyupward angled side frame section, h. said side enclosures, said straightframe section and said cover retainers are relatively spaced anddimenSioned such that said cover retainers are adjustably engageablewith said side frame sections to when positioned form said caminterfitting means to compress said modules between said cover and saidsupport base in said releasable engagement, and i. said box of each ofsaid modules further comprises:
 1. a tab extending angularly verticallyfrom said box to provide a surface against which a next verticallystackable module in said rack abuts to provide vertically stepped rowsof said modules in said rack substantially angularly following thedirection of said rearwardly upward angled frame section.
 2. a doubleangularly bent frame member having a normally horizontal upper sideframe section and a normally rearwardly upward angled side framesection, h. said side enclosures, said straight frame section and saidcover retainers are relatively spaced and dimenSioned such that saidcover retainers are adjustably engageable with said side frame sectionsto when positioned form said cam interfitting means to compress saidmodules between said cover and said support base in said releasableengagement, and i. said box of each of said modules further comprises:2. retaining said end within the loop and drawing said wires along saidfirst surface, around said grooved front end, along said second surfaceand any remaining wire length over said loop to form wire bightsadjacent said grooved front surface, bifurcated wire ends along saidsurfaces, and remaining wire ends dangling in a plane behind the loop,c. inserting said divider to box loaded position into an open-ended boxhaving a means to releasably receive said divider in loop protrudinglocked in relationship whereby said remaining wire lengths danglesubstantially in a plane rearwardly immediately beyond said loop, andsaid bights are accessible from the front by the fingers of a hand, andhaving an angled angularly protruding tab, d. stacking in predeterminedarray a plurality of said loaded boxes in a rack in rows such that theend surfaces of the boxes of each row above the bottom row are stackedagainst one of the sides of the tabs of columnarly corresponding boxesof the next vertically disposed row to thereby stack the boxes instepped backward relationship such that the remaining wires lengthsdangle in separate planes for each row; and e. compressingly securingsaid loaded boxes in the rack
 2. a removable elongated wire supportingbox divider contoured to fit in longitudinally extending relationshipwithin said box, said divider having wire supporting and retaining meansadapted to be loadable with and to retain wires in box removedcondition, and
 2. A modular wire storage and dispensing station tofacilitate assembly of units having wire components comprising: a. arack, said rack further comprising:
 2. a pair of side enclosures, and 2.a pair of said enclosures, and
 2. a removable elongated wire supportingbox divider contoured to fit in longitudinally extending relationshipwithin said box, said divider having wire supporting and retaining meansadapted to be loadable with and to retain wires in box removedcondition, and
 2. a compressible material flat spring forwardlyextending from the lower end of said loop to form an obtuse angle withsaid divider bottom supporting surface with the spring forward endpositioned in spring uncompressed condition below said box bottom wallwhen said divider is aligned to be inserted into said box, and
 2. meansto attach said box enclosable wall perpendicularly to said flat platedivider section,
 3. a first and a second U-shaped wall spaced to receivesaid flat divider section and the rear ends of said rails therebetweenand dimensioned to bearingly slide within the rear top, bottom, and sideportion within said box.
 3. The modular wire storage and dispensingstation of claim 2 wherein: a. said box sides are forwardly downwardlychamfered from said top at the front and said top terminates at thefront rearwardly of said bottom at the front thereby facilitating humanfinger accessibility and vision from the front, b. said rails comprisetop rails and bottom rails protruding from said box sides, c. said boxhas an open rear end, d. said divider when inserted into said boxextends beyond said box open rear end, e. said divider has a reverselydownwardly bent loop disposed at its rear end to support wire endsextending thereover such that the wire ends dangle substantially in aplane immediately to the rear of the plane defined by the rear surfaceof said loop, f. said means to lock said divider further comprises acompressible spring section formed of elastic material and bent forwardsfrom the lower end of said loop at an obtuse angle to said elongateddivider section and bent substantially perpendicularly downwards at itsforwardly terminating end to form a tongue, the spacing between saidspring section in uncompressed condition and said elongated dividersection being larger than the spacing between said bottom rails and saidbox bottom, said spriNg being compressible between human fingers suchthat said tongue clears said box bottom when said elongated dividersection is slid in the groove between said top and bottom rails, g. saidbox bottom has a slot rearwardly disposed, said tongue and said slot areparallel and said tongue and said slot are dimensioned and positioned tolockingly interfit when the divider is in operative inserted wirestoring and dispensing position, h. said box has an identification tabangularly disposed to its axis and protruding to enable rearwardlystepped stacking of superimposed modules.
 3. A substantially downwardlyextending tongue terminating said spring and of dimensions to beengagingly received in said slot, h. said means to slide said dividerfurther comprises a pair of rails inwardly protruding from each saidsidewall of said box and spaced to receive one of said side edges ofsaid divider, said box inward sidewalls being spaced to receive saiddivider between said opposite side edges, i. said divider is of greaterlength than said box, j. said wire bight retaining front surface meansfurther comprises a pair of forwardly extending fingers and a recessedcenter front section defining a groove in which wire bights aredisposed, and k. said divider fingers at the forward end aresubstantiAlly contiguous with the adjacent box forward side edges whensaid tongue is engaged in said slot such that said bights disposed insaid front section groove are in said bight graspable position.
 3. meansto removably secure said divider in said box such that upon loadingwires thereon said divider may be inserted into and retained in said boxto divide said box into chambers to temporarily store said wires inposition for removal through said box open front end; and wherein: c.said rack support base and side enclosure are of frame construction, d.said modules are formed of elastic material and are of width withrelation to said side enclosures such that a predetermined number ofsaid modules are frictionally slidably contained in one of said rows, e.said cover further comprises a cam interfitting means to compress saidmodules between said cover and said support base to clampingly securesaid modules therebetween in releasable engagement, f. said caminterfitting means further comprises a substantially U-shaped coverfront frame member having a straight frame section terminated at eachend by a cover retainer angularly bent with respect to said straightframe section, g. said side enclosures each further comprises:
 3. acover, b. a plurality of wire storage and dispensing modules removablystackable between said side enclosures and between said base and saidcover of said rack, each of said modules further comprising:
 3. a cover,a plurality of wire storage and dispensing modules removably stackablebetween said side enclosures and between said base and said cover ofsaid rack, each of said modules further comprising:
 3. means toremovably secure said divider in said box such that upon loading wiresthereon said divider may be inserted into and retained in said box todivide said box into chambers to temporarily store said wires inposition for removal through said box open front end, c. said box,divider, and means to movably retain said divider further comprising: d.a box top, e. a box bottom, f. an elongated flat plate divider sectionhaving a bottom surface, a top surface and a front surface defining awire bight receiving groove to enable drawing of said wire along saidbottom surface, around said front groove defining surface and along saidtop surface for said wire loading and retaining, g. a pair of railsprotruding from the inside of each of an opposing two of said top,bottom and sides, said rails being separated to form a groovetherebetween, h. said divider being of dimensions with relation to thespacing between said opposing two insides and between said grooves to beslidably movable within the rails to divide said box into chambers suchthat said divider may be removed for loading, loaded, and reinsertedwithin said box, and i. means to lock said divider into position withinsaid box where said front wire bight receiving groove is accessible byhuman fingers from said box front open end.
 4. The modular wire storageand dispensing station of claim 2 wherein: a. said box sides areforwardly downwardly chamfered from said box top at the front and saidtop terminates at the front rearwardly of said bottom at the front, b.said rails comprise top rails and bottom rails protruding from said boxsides, c. said means to secure said divider further comprises:
 5. Instation means to store prepared wires and to assemble said wires intoequipment, a wire storage and dispensing module comprising: a. anelongated box having top, side, and bottom walls and having open frontand rear ends, b. a box divider having supporting surfaces including afront surface to retain a wire bight and top and bottom supportingsurfaces to support wire bifurcated ends, c. means to slide said dividerselectively into box inserted condition wherein said wire bightretaining front surface is accessible from said box front end and saidbox is divided into wire end storing chambers, or to box removedcondition to enable a wire to be drawn around said divider in bent wireconfiguration to form a bight and bifurcated ends such that said wirebight is disposed at said divider front surface and said wire ends aredisposed along said bifurcated end top and bottom supporting surfaces,d. means to secure said divider in said box in bight graspable position,e. said box front end sidewalls being bevelled downwardly and forwardlyfrom said top wall, and said bottom wall extending forwardly of said topwall, to facilitate vision and grasping of said bight, f. and whereinsaid box bottom wall has a slot near its rear wall end, g. said dividerfurther comprises:
 6. A method of manufacturing a unit containing wirescomprising the steps of: a. preparing groups of the wires; b. placing inproximity respectively each of said groups of wires, and for each ofsaid groups a separable wire mountable box divider having first andsecond surfaces and a front end, and a divider retainable box having anopen front end; c, drawing the wires of each of said groups along saidfirst surface, around said front end, and along said second surface ofsaid group respective divider to form bights at the front end andbifurcated wire sections; d. inserting each of said respective dividersinto its said respective box to form therewith respective wire groupstoring and dispensing modules each having a first and a second chamberand a wire bight accessible open front; and e. stacking said modules ina rack in rows comprising at least one row; f. at least one of saiddividers having a rear downwardly reversely bent loop, said drawing stepfurther comprising: g. positioning one end of the respective groups ofwires of the at least one downwardly reversely bent box divider withinthe loop; h. retaining said one end within the loop while drawing saidlast-named group of wires along said first surface, then around saidfront end, and then along said second surface of said box dividers; andi. draping any of said last-named wires which are longer than the lengthof said combined first and second bifurcated wire sections along saidfirst and second surfaces and said bight, over said loop to danglesubstantially in a plane rearwardly of said loop.
 7. The method of claim6, said stacking step further comprising: a. arranging said modules inupward progressively stepped back rows such that said longer wires ofeach said row of modules dangles in a substantially separate plane.
 8. Amethod of assembling a unit comprising the steps of: a. preparing groupsof wires at a wire preparing station, b. mounting each of said groups atsaid preparing station upon a divider having first and second surfaces,a grooved front end, and a rear downwardly bent loop, said mountingfurther comprising:
 9. The method of claim 8 including: a. selectivelyloading additional dividers into boxes, and b. deleting, inserting andrearranging said loaded boxes including said additional loaded boxes inaccordance with currently changed composition, characteristics andnumbers of wires required for said unit.
 10. The method of cLaim 8including: a. marking indicia and placing such indicia upon said boxesin accordance with designation of the wires contained in said boxes.